Composite structural panels and components

ABSTRACT

Composite panels including core layers of particular geometry and optional first and second skin layers. The components optionally are made from fiberboard material. The core has either a linear geometry or made from discrete elements. In exemplary embodiments, longitudinally extending voids extend through the panel. Electrical or mechanical conduits may be inserted through the longitudinally extending voids.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. application No. 61/841,237,entitled, “Composite Structural Panels and Components”, and which wasfiled Jun. 28, 2013, the entirety of which is referred to andincorporated herein by this reference in its entirety.

FIELD OF THE DISCLOSURE

The disclosure that follows relates to structural panels derived fromcomposite materials.

BACKGROUND

Although there are a wide variety of known materials and techniques toproduce traditional structural panels, improvements upon the materialsor techniques may produce a more versatile panel, with improvedtransportability and functionality. Moreover, there is a need formaterials and techniques that reduce consumption of nonrenewableresources, and still provide cosmetic and functional appeal.Accordingly, there is a need for structures and techniques forassembling composite structural panels, and which optionally arefabricated of renewable or waste resources.

Traditional structural panels are solid pieces of material sandwichedbetween two boards. These traditional panels offer benefits such asinsulation. They do not, however, provide for plumbing through theirinner cores. There is a need for panels with hollow interiors that canprovide conduits for electrical and mechanical features.

SUMMARY

The present disclosure, in its many embodiments, alleviates to a greatextent the disadvantages of a high density traditional structural panelsby providing a sandwich type of construction in which two planar skinlayers are affixed to a central core of a specified geometry. Thecentral core serves to spatially separate the planar skin layers and inan embodiment also forms inner voids between portions of the inner coreand/or portions of the inner core and a skin layer. In some embodiments,mechanical elements such as ducting, wiring or other elements may bepositioned within the void spaces. Alternatively, the voids may serve asfluid transit ducts such as for ventilation purposes.

In one embodiment of the invention, a composite panel is formed fromfiberboard material. A bottom side of a first sheet and a top side of asecond sheet are attached to an inner core forming the panel. The innercore may have a liner geometry. The linear geometry has a corrugatedinterior shape.

The inner core may also be comprised of discrete elements. The discreteelements may be of any desired geometry, such as cones, overlappingpyramids, non-overlapping pyramids or longitudinally extending ridges.The discrete elements may be aligned to form a longitudinally extendingvoid from one end of the panel to the other. Electrical or mechanicalconduits may be inserted into the longitudinally extending voids.

It is an object of the present invention to provide composite panelsthat are lightweight yet retain a desired shape. Due to the relativelylow weight to surface area ratio, the panels may be handled byrelatively light equipment or crews. The panels may be loaded andtransported on the back of a pickup truck and be assembled in remotelocations.

Other objects of the present invention will become more evidenthereinafter in the specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects of the disclosure will be apparent uponconsideration of the following detailed description, taken inconjunction with the accompanying drawings, in which:

FIG. 1 is an elevation view of a panel in accordance with an embodimentof the invention;

FIG. 2 is an elevation view of an inner core in accordance with theinvention;

FIG. 3 is a perspective view of a panel in accordance with an embodimentof the invention;

FIG. 4 is a perspective view of an inner core in accordance with anembodiment of the invention;

FIG. 5 is a plan view of an element in accordance with an embodiment ofthe invention;

FIG. 6 is a perspective view of an element in accordance with anembodiment of the invention;

FIG. 7A is a perspective view of an inner core in accordance with anembodiment of the invention;

FIG. 7B is a perspective view of an inner core in accordance with anembodiment of the invention;

FIG. 8A is a plan view of an inner core in accordance with an embodimentof the invention;

FIG. 8B is a cross-sectional view taken along line 5-5 in FIG. 8A of aninner core in accordance with an embodiment of the invention;

FIG. 8C is a cross-sectional view of an inner core in accordance with anembodiment of the invention;

FIG. 9A is a perspective view of an inner core with an embodiment of theinvention;

FIG. 9B is a detail perspective view of an inner core in accordance withan embodiment of the invention;

FIG. 9C is a cross-sectional view taken along line 5-5 in FIG. 9B of aninner core in accordance with an embodiment of the invention;

FIG. 10A is a perspective view of an inner core in accordance with anembodiment of the invention;

FIG. 10B is a detail perspective view of an inner core in accordancewith an embodiment of the invention;

FIG. 10C is a top plan view of an inner core in accordance with anembodiment of the invention;

FIG. 10D is a cross-sectional view taken along line 5-5 in FIG. 10C ofan inner core in accordance with an embodiment of the invention;

FIG. 11A is a perspective view of an inner core in accordance with anembodiment of the invention;

FIG. 11B is a detail perspective view of an inner core in accordancewith an embodiment of the invention;

FIG. 11C is a perspective view of an element of an inner core inaccordance with an embodiment of the invention; and

FIG. 11D is a cross-sectional view taken along lines 5-5 and 6-6 in FIG.11B of an inner core in accordance with an embodiment of the invention.

FIG. 12 is a perspective view of a panel in accordance with anembodiment of the invention.

FIG. 13 is a perspective view of a panel in accordance with anembodiment of the invention.

FIG. 14 is a perspective view of a panel in accordance with anembodiment of the invention.

FIG. 15 is a perspective view of a panel in accordance with anembodiment of the invention.

FIG. 16 is a perspective view of a panel in accordance with anembodiment of the invention.

DETAILED DESCRIPTION

In the following paragraphs, embodiments will be described in detail byway of example with reference to the accompanying drawings, which arenot drawn to scale, and the illustrated components are not necessarilydrawn proportionately to one another. Throughout this description, theembodiments and examples shown should be considered as exemplars, ratherthan as limitations of the present disclosure. As used herein, the“present disclosure” or “present invention” refer to any one of theembodiments described herein, and any equivalents. Furthermore,reference to various aspects of the invention throughout this documentdoes not mean that all claimed embodiments or methods must include thereferenced aspects or features.

An example of a panel 10 is illustrated in FIG. 1. The panel 10 has aninner core 20 of a predetermined geometry, a first sheet or skin 30,which is illustrated as a top sheet, and a second sheet or skin 40,which is illustrated as a bottom sheet. It should be appreciated thatwhen used as a wall panel, one of the sheets 30, 40 may be orientedtowards the inside of a room and the other one of the sheets 30, 40 maybe oriented towards either the inside of a two panel wall, or the insideof an adjacent room or the exterior of a structure. Each of the sheets30, 40 has an inner surface 32, 42 oriented toward the interior of thepanel 10, and an outer surface 34, 44 oriented toward the exterior ofthe panel 10. Any structure and geometry may be selected for inner core20 in the present invention that achieves desired structuralcharacteristics, such as stiffness, strain resistance and interior voidscreation. The terms “skins” or “sheets” are being used for namingpurposes only and not for purposes of limitation, as are the terms “topsheets” and “bottom sheets.”

In the illustrated embodiment, it is seen that the inner core geometryforms plural longitudinally extending interior voids 120 between walls25 of the inner core 20 geometry and the inner surfaces 32 and/or 42 ofone or more of the sheets 30, 40.

The panel 10 and its components, such as the sheets 30, 40 and core 20may be formed of any materials that will impart the physical propertiesand structural integrity desired. Examples of some materials thesecomponents include cardpanel, paperpanel, wood, cellulosic composites,compressed cellulose material blends, brass, stainless steel, or othermetals, polymeric materials or other cellulosic based products, orcombinations of these materials. Some examples of suitable molded and/orcompressed cellulose based materials are discussed in commonly ownedU.S. Pat. No. 8,297,027, entitled, “Engineered Molded Fiberboard Panelsand Methods of Making and Using the Same” and U.S. Pat. No. 8,475,894,entitled, “Engineered Molded Fiberboard Panels, Methods of Making thePanels, and Product Fabricated From the Panels,” both of which arereferred to and incorporated herein in their entireties.

Illustrated in FIG. 2 is a cross section of an inner core structure. Inthis embodiment, inner core 20 has a wave or corrugated structure. Thecorrugated structure features angled flanges 50 positioned betweenalternating peaks 60. The top and bottom skins (not shown in FIG. 2) areaffixed to the respective alternating peaks 60. In some embodiments, thetop and bottom skins are affixed to their respective peaks 60 by anadhesive layer. Any suitable adhesive may be selected that provides adesired level of adhesion, heat expansion or contraction, longevity etc.between the peaks 60 and the top and bottom skins.

Two general examples of suitable geometries for the inner core 20 areshown in FIGS. 3 and 4. FIG. 3 illustrates a panel with a lineargeometry in its inner core. FIG. 4 illustrates an inner core with adiscrete geometry. In the case of a linear geometry, a cross-sectionalprofile exceeds the length of panel 10. Stated another way, the innercore geometry extends from one end of panel 100 to the other end ofpanel 110. The space between the inner core and the top and bottom skinsform void spaces. These void spaces are longitudinally extending voids120 spanning from one end 100 to the other end 110.

Shown in FIG. 4 is a discrete geometry. The inner core includes paralleldiscrete elements 27. Typically, a discrete element 27 has a peak 28bordered by axially extending side walls 29. The angle and dimensions ofthe sidewalls 29 and the dimensions of the peaks 28 may vary to formdifferent discrete geometries. Two examples of possible discretegeometries that can be achieved through the present invention are shownin FIGS. 5 and 6. For example, the discrete element 27 in FIG. 5 has abroad peak 28 with acute angled, small sidewalls 29. The discreteelement 27 in FIG. 6 has a narrow peak 28 with acute angled, longsidewalls 29. The discrete element 27 in FIG. 5 has a box-like shape,whereas the discrete element 27 in FIG. 6 has a pyramid-like shape.

FIGS. 7 through 11 illustrate some of the many embodiments of the innercore 20 provided by the present invention. Shown in these Figures areperspective views, detailed perspective views, plan views, detailed planviews and elemental perspective views of the inner core embodiments.Generally, as described earlier, top and bottom skins sandwich the innercore. For illustration purposes, these skins are not illustrated inFIGS. 7 through 11.

FIGS. 7A and 7B show a perspective view and a detailed perspective viewof inner core 20. As shown in FIGS. 7A and 7B, this embodiment has alinear geometry with a corrugated structure 50, 60. The linear featureof this embodiment spans from end 100 of corrugated inner core 20 to theopposing end 110 of corrugated inner core 20. After the top and bottomskins are affixed to the corrugated inner core 20, open space 120defining longitudinally extending voids are formed between the innercore and the skins.

Optionally mechanical or electrical elements may be positioned withinone or more of the longitudinally extending void spaces 120 of thisembodiment. Examples of such mechanical or electrical elements mayinclude ventilation ducts, wires, lighting, cables, plumbing orconduits. The void spaces provide a protected conduit through the panel.The electrical or mechanical element need not pass through the entirelongitudinally extending void space but may terminate at any point inthe void 120.

FIG. 8A is a plan view of the corrugated inner core 20 of thisembodiment. FIGS. 8B and 8C are a cross sectional view and a detailedcross sectional view of the corrugated structure. The corrugatedelemental features have angled flanges 50 positioned between alternatingpeaks or surfaces 60. It should be understood that the angles of theflanges can vary. Sharper angles or more obtuse angles are possible. Itshould be further understood that the lengths of the alternating peaksor surfaces can vary. By adjusting the angles of the flanges 50 and thelengths of the peaks 60, multiple embodiments of longitudinallyextending voids 120 derived from a corrugated wave structure arepossible. Larger voids may be constructed by providing an obtuse anglewith larger peaks. It should be appreciated that by increasing the widthof the longitudinally extending voids, the number of voids per panel isdecreased. Increased widths of the void spaces allow for the passage oflarger mechanical or electrical instrumentalities.

Conversely, the widths of the void spaces may be decreased by shorteningthe lengths of peaks 60 and decreasing the angles of the angled flanges50. It should be appreciated that by decreasing the size of the voidspaces, the number of voids per panel is increased. Increasing thenumber of voids per panel allow for increased electrical or mechanicalconduits. In addition, because the longitudinally extending voids areisolated from each other, additional insulation to electrical ormechanical instrumentality inside the void is provided. It should alsobe appreciated that both small and large voids may be implemented withinthe same panel, if that is a desirable feature.

FIGS. 9 through 11 disclose embodiments with discrete elements in theinner core. FIGS. 9A and 9B are a perspective view and a detailedperspective view of an inner core 80 featuring a discrete element. Asshown in FIG. 9B, element 200 of inner core 80 has a pyramid-likestructure with peaks 28 bordered by axially extending sidewalls 29. Forthe purpose of naming and not of limitation, this structure will bereferred to as a pyramidal embodiment. Although the pyramidal embodimentfeatures a discrete element in the shape of a pyramid 200 that is notcontinuous for the length of the panel, such as the inner core in theembodiments illustrated in FIGS. 7-8, the pyramidal discrete elements200 may be aligned in parallel rows such that open spaces defininglongitudinally extending voids span from one end 100 of panel 80 toopposite end 110. Optionally, electrical and mechanical elements may beinserted into the longitudinally extending void spaces. The electricalor mechanical element need not pass through the entire longitudinallyextending void space but may terminate at any point in the void 120.

FIG. 9C is a cross sectional view of the pyramidal embodiment of FIGS.9A-9B. The cross section shows a corrugated structure with angledsidewalls 29 alternating between peaks 28. Similar to the corrugatedstructure of FIGS. 7-8, the void spaces in the pyramidal embodimentstructure can be varied in width and height. Sharper angles or moreobtuse angles between the sidewalls 29 and peaks 28 are possible. Itshould be further understood that the lengths of the alternating peaks28 are variable. By adjusting these features, multiple embodiments oflongitudinally extending voids derived from discrete elements 200 in theinner core 20 are possible. Larger voids may be constructed by providingan obtuse angle between sidewalls 29 and peaks 28. Larger voids are alsomade possible by increasing the length of the peaks 28. Smaller voidsmay be constructed by decreasing the angle between sidewalls 29 and peak28. Smaller voids are also made possible by decreasing the length ofpeaks 28. By increasing the size of the void spaces, there will be lessvoids per panel. By decreasing the size of the void spaces, there willbe more voids per panel. The number and size of the longitudinallyextending voids 120 are dependent upon the characteristics of theelectrical or mechanical elements to be inserted into them. It should befurther appreciated that both small and large voids may also beimplemented within the same panel 10, if that is a desirable feature.

FIGS. 10A and 10B illustrate another embodiment of inner core featuringdiscrete elements 300 with a conical geometry. FIG. 10B is a detailedperspective view of the discrete element 300. Conical discrete element300 is formed by peaks 360 bordered by axially extending roundedsidewalls 350. For the purpose of naming and not of limitation, thisstructure will be referred to as a conical embodiment. Although theconical embodiment of FIGS. 10A-10B has a discrete element 300 that isnot continuous for the length of the panel, the conical discreteelements 300 may be aligned in parallel rows such that open spacesdefining longitudinally extending voids span from one end 100 of panel10 to the opposite end 110. Optionally, electrical and mechanicalelements may be inserted into the longitudinally extending void spaces.The electrical or mechanical element need not pass through the entirelongitudinally extending void space but may terminate at any point inthe void 120.

FIG. 10C shows a plan view and FIG. 10D shows a cross sectional view ofthe conical embodiment. The cross section depicts a semi-corrugatedstructure with peaks 360 bordered by axially extending rounded sidewalls350. Similar to the corrugated structure of FIGS. 7-8 and the pyramidalembodiment of FIGS. 9A-9C, the void spaces in the conical embodimentstructure may be varied in width and height. Sharper angles or moreobtuse angles between rounded sidewalls 350 and peaks 360 are possible.It should be further understood that the lengths of the peaks 360 arevariable. By adjusting the angles of the sidewalls and the lengths ofthe peaks, multiple embodiments of longitudinally extending voids arepossible. Larger voids may be constructed by increasing the anglebetween the rounded sidewall 350 and peak 360. Larger voids may also beconstructed by increasing the size of peaks 360. Smaller voids may beconstructed by decreasing the angle between the rounded sidewall 350 andpeak 360. Smaller longitudinally extending voids may also be constructedby decreasing the size of peaks 360. An increase in the size of the voidspaces results in less voids per panel. Conversely, decreasing the sizeof the void spaces results in more voids per panel. The number and sizeof the longitudinally extending voids 120 is dependent upon thecharacteristics of the electrical or mechanical elements inserted intothem. It should be further appreciated that both small and large voidsmay also be implemented within the same panel, if that is a desirablefeature.

Another possible shape for an inner core discrete element is shown inFIGS. 11A through 11D. In this embodiment the discrete element 400 ishexagonally or egg-crate shaped with four axially extending sidewalls410 surrounding peak and valley surfaces 420. For the purpose of namingand not of limitation, this structure will be referred to as a hexagonalembodiment. Unlike the previously disclosed embodiments, the open spacebetween the inner core 95 and the top and bottom skins 30, 40 of thehexagonal embodiment does not define a longitudinally extending void.The hexagonal embodiment has a more undulated inner core than thepreviously disclosed embodiments. The hexagonal embodiment's increasedundulation provides the panel with greater insulating characteristics.

A variety of embodiments are possible by either increasing or decreasingthe number and/or arrangements of skins 30, 40 or the number and/orarrangements of inner cores 20 or both. For example, a panel may becreated without one or both of the top and bottom skins 30, 40.Illustrated in FIG. 12 is an embodiment of a panel 10 with two innercores stacked on top of one another. Each of the inner cores 80 has adiscrete element geometry 200 of the pyramidal embodiment shown in FIGS.9A-9B. The top inner core 80 is flipped upside down and affixed onto thetop of the bottom inner core 80. It should be appreciated that bystacking the top inner core 80 upside down on top of the bottom innercore 80, taller longitudinally extending void spaces 120 may beproduced. Taller voids 120 are adaptable to larger electrical andmechanical elements being inserted into them. Optionally first andsecond skin layers 30, 40 may also be included in this embodiment. Italso should be noted that in the embodiments discussed herein whereskins 30, 40 are not provided, although the structures shown arereferred to as “inner core,” for purposes of continuity with thedescription of other embodiments, in the non-skin embodiments, surfacesof the inner cores 20 are exposed.

FIG. 13 shows another embodiment of a panel 10, including inner cores 20in stacked relation to one another. Similar to the embodiment shown inFIG. 12, top and bottom skins 30, 40 are not included, but optionally inan alternative embodiment, they can be included. Each of the inner cores20 has a linear geometry with the one of the inner cores rotated withrespect to the other. In the illustrated embodiment, the first or topinner core 20 is rotated 90 degrees relative to the second or bottominner core 20. Longitudinally extending void spaces 120 are provided inboth the x and the y directions. Optionally, electrical and mechanicalelements may be routed in either direction through the longitudinallyextending voids 120. The electrical or mechanical element need not passthrough the entire longitudinally extending void space but may terminateat any point in the void 120. It should be appreciated that thisembodiment provides an increased number of void spaces.

If desired, additional layers of inner cores 20 may be added. In oneexample illustrated in FIG. 14, four stacked inner core layers 20 areprovided. In this embodiment, the top and bottom inner cores 200 and 215are orientated in the same direction, and the two middle inner cores 205and 210 are rotated 90 degrees relative to the top and bottom innercores 200, 215. The two middle layers are stacked with their peakstouching, and optionally affixed to one another, for example usingadhesive or mechanical fasteners, as in other embodiments where layersof inner cores are positioned adjacent to one another. Longitudinallyextending void spaces 120 are provided in both the x and y directions.For example, longitudinally extending void spaces 120 in the x directionare formed between the bottom layer 215 and one of the middle layers 210and also between the top layer 200 and inner layer 205. Likewise,longitudinally extending void spaces 120 in the y direction are formedbetween the two middle layers 205, 210. Depending on the requirementsand specifications of the composite structural panel, it is possible toadd additional inner core layers to the embodiment shown in FIG. 14. Forexample, another two layers arranged like layers 205 and 210 are withrespect to each other may be positioned adjacent the free side of layer200, or layer 215. Additional inner core layers will add thickness tothe panel and provide additional longitudinally extending voids.

In other embodiments, multiple inner core layers 20 are provided withskin layers 30 and/or 40. FIG. 15 illustrates an embodimentcorresponding to that of FIG. 13, but with first and second skins 30, 40included. Likewise, FIG. 16 illustrates an embodiment corresponding tothat of FIG. 16, but with first and second skins 30, 40 included.

Additional embodiments of multiple layers of discrete element geometryinner cores with skins are possible. In some embodiments, liner geometryinner cores are layered on discrete element geometry inner cores withskins separating the inner cores. It should be appreciated that anycombination and number of inner cores may be included in a compositestructural panel depending upon the design specifications and desirablefeatures.

Many advantages of composite panels made from fiberboard materials havebeen described above. An additional advantage of the composite panels intheir many embodiments is their weight. The panels are lightweightbecause of their low-density inner cores. Thus, the panels may be sizedso that they can be easily loaded, unloaded and assembled by no morethan two people. Due to their light weight, the panels are easilytransportable. A pick-up truck can carry a load of panels to remote andisolated locations for easy assembly and disassembly. Further, thepanels are fully recyclable and reusable. They can be disassembled andreused at another location.

Thus, it is seen that composite structural panels and components areprovided. It should be understood that any of the foregoingconfigurations and specialized components may be interchangeably usedwith any of the apparatus or systems of the preceding embodiments.Although illustrative embodiments are described hereinabove, it will beevident to one skilled in the art that various changes and modificationsmay be made therein without departing from the scope of the disclosure.It is intended in the appended claims to cover all such changes andmodifications that fall within the true spirit and scope of thedisclosure.

What is claimed is:
 1. A composite panel comprising: at least two innercores made from fiberboard material, each inner core has a definedgeometry and is layered on top of each other; and a plurality of openspaces formed between the defined geometries of the inner cores.
 2. Thecomposite panel of claim 1 wherein the defined geometry of the innercore is linear.
 3. The composite panel of claim 1 wherein the inner corehas a discrete element geometry.
 4. The composite panel of claim 2wherein the open space forms at least one longitudinally extending void.5. The composite panel of claim 4 further comprising an electricalelement into the at least one longitudinally extending void.
 6. Thecomposite panel of claim 4 further comprising a mechanical elementinserted into the at least one longitudinally extending void.
 7. Thecomposite panel of claim 3 wherein the open space forms at least onelongitudinally extending void.
 8. The composite panel of claim 7 whereinthe discrete elements have a pyramid shape.
 9. The composite panel ofclaim 7 wherein the discrete elements have a conical shape.
 10. Thecomposite panel of claim 3 wherein the discrete elements have ahexagonal shape.
 11. A composite panel comprising: a first sheet madefrom fiberboard material; a second sheet made from fiberboard material;an inner core with a defined geometry made from fiberboard material,wherein the first sheet is affixed to the top side of the inner core andthe second sheet is affixed to the bottom side of the inner core; and atleast one longitudinally extending void space formed between the top andbottom sheets and the defined geometry of the inner core.
 12. Thecomposite panel of claim 11 wherein the defined geometry of the innercore is linear.
 13. The composite panel of claim 11 wherein the definedgeometry of the inner core has a discrete element geometry.
 14. Thecomposite panel of claim 13 wherein the discrete element geometry isconical.
 15. The composite panel of claim 13 wherein the discreteelement geometry is in the shape of a pyramid.
 16. The composite panelof claim 13, wherein the discrete element geometry is hexagonal.
 17. Thecomposite panel of claim 11 further comprising one or more inner coresand one or more sheets affixed on top of each other.
 18. A method offorming a composite panel comprising: providing a first and second sheetmade from fiberboard material; providing an inner core made fromfiberboard material with a top side and a bottom side; affixing thefirst sheet to the top side of the inner core; and affixing the secondsheet to the bottom side of the inner core.
 19. The method of formingthe composite panel of claim 18 wherein the inner core has a lineargeometry.
 20. The method of forming the composite panel of claim 18wherein the inner core has a discrete element geometry.